Heat sealable polyethylene laminate and method of making same



K. HEUSER ETAL E POLYETHYLENE LAMINATE Feb. 12, 1963 R HEAT SEALABL AND METHOD OF MAKING SAME Filed June 29, 1956 l0 Exfruder lner? Gas flfi id Extrusion we {2 Z2 17 B 2 To Wind up Assembly ATTORNEY United States Patent 3,077,423 HEAT SEALABLE POLYETHYLENE LAMINATE WTHGD Q1 MAKHNG SAME Rhoda C. K. Heuser, Rochester, N.Y., and Waiter A. Hanna, Scotch Plains, N.J., assi nors to Union Carbide Corporation, a corporation of New York Filed June 29, 1956, Ser. No. 594,928 Ciaims. (Cl. 154-50) This invention relates to a process for improving the heat scalability of polyethylene surfaces to each other.

More particularly the invention is concerned with a treatment of polyethylene in film form whereby one planar surface is treated to impart satisfactory adhesion to another polyethylene surface, and the other planar surface is treated to impart satisfactory adhesion to nonpolyethylenc surfaces such as paper, metallic foil, cellophane and like sheet materials to form therewith composite sheet or laminated structures capable of being sealed by hot-pressing together the polyethylene surfaces of the composite sheets.

These laminated materials are useful as wrapping or packaging materials, chemical-barrier materials and fabrication sections. Polyethylene coatings provide good resistance to chemicals such as acids and bases which ciellophane, aluminum, and other substrates do not possess a one.

In the continuing search for new and improved packaging, barrier and fabrication materials, it has been found that common materials of limited application such as paper, foil and cellophane can be materially benefited when combined with polyethylenic sheeting or film. A conventional means for upgrading paper and the like that has found wide acceptance comprises extruding a film of polyethylene and bringing the hot film into intimate contact with the paper substrate and bonding it to the substrate by application of pressure.

Such upgraded materials have better moisture resistance and water vapor resistance, have improved strength and are more resistant to chemical attack.

However, polyethylene films extruded at the temperatures normally used for unsupported flat film extrusion, e.g., about 210 C., are not generally suit-able for this purpose. The adhesive characteristics of the film are unsatisfactory for bonding the film to a substrate, par ticularly a smooth-surfaced substrate such as metal foil. Elevated temperatures, generally about 50 C. higher than the normal extrusion temperatures, must be employed to obtain satisfactory-adhesion between the film and substrate.

While extrusion at such elevated temperatures improves the adhesive characteristics of polyethylene film, it severe- 1y injures the heat scalability of the film. Also, the high temperature fosters degradation of the polyethylene as may be evidenced by an increased tendency for rancid odor formation, discoloration, and blocking, the tendency for sheets of polyethylene to stick to each other, even though surface tackiness is not apparent.

By heat scalability is meant the ability of polyethylene to bond to itself by conventional heat sealing means such as bringing together two polyethylene areas for about three seconds at about 350 F. under a pressure of about 4O p.s.i. eat scalability finds importance, for example, in efiecting closure of polyethylene-coated bags.

Surface treatment of a polyethylene coating that has been extruded at high temperature may improve the heat scalability. Such treatment comprises buffing or abrading the surfaces to be sealed. As might be expected, however, the appearance of the coating is impaired and the discoloration, blocking, and increased susceptibility for subsequent development of rancid odor that may accompany high-temperature extrusion remain problems that impose serious limitations on the application of the final product.

A technique that is currently employed comprises high temperature extrusion of a polyethylene film with subsequent bonding to a non-polyethyienic substrate. A second polyethylene film is then extruded at a lower temperature and is bonded to the exposed surface of the high-tempcrature-extruded film. Obviously this technique cannot be employed Where thin coatings are desired or required. As with the previously described method, this method requires additional process equipment and additional process operations.

The previously described methods are concerned with improving the heat scalability of the final product. However, it might be possible to produce a product having poor heat scalability and then resort to the more drastic sealing conditions such as higher sealing temperatures, pressures and times required by such a product. However, higher sealing temperatures and pressures cause the polyethylene to flow away from the seal area and weak seals result. Seals made at the lower temperatures and pressures currently in practice exhibit greater strength than those made under more drastic conditions; the latter are too weak for most applications.

Poor heat scalability is not necessarily manifest immediately; it may appear after coated materials have been stored for a few months, even at room temperature.

The extent to which heat scalability and the other properties of polyethylene are degraded by exposing the polyethylene to elevated temperature depends on both the temperature and the duration of exposure. For example, polyethylene subjected to even the normal unsupported-fiat-film-extrusiou temperature for an extended period of time may suffer a reduction in heat scalability and show signs of general degradation as discussed previously. Alternatively, if polyethylene is to be subjected to elevated temperatures for only a short time, a higher temperature is permissible than can be tolerated for a longer period of time.

It is an object of this invention to provide a method for firmly bonding a film of normally-solid polyethylene composition to a non-polyethylenic substrate wherein the heat scalability of the polyethylene film is retained substanti ally unimpaired.

It is another object to provide a means for minimizing high-temperature degradation of polyethylene as evidenced by the development of rancid odor, discoloration, blocking and reduced heat scalability following hightemperature treatment of the polyethylene.

Other objects will be apparent from the discussion of the invention.

The objects are achieved by maintaining the polyethylene composition in an inert atmosphere from the time of extrusion until the material is cooled, thereby substantially shielding the material from oxygen and its degrading influence.

The invention may be more clearly understood b reference to FIGURE 1.

The apparatus of the drawing schematically represents an extrusion die 10, for extruding polyethylene film, rolls 15 and 16, for bonding the film to the substrate, and gas manifold 17, for maintaining an inert gas shield on the film surface until the film solidifies.

A film of normally-solid polyethylene 12 is extruded downward from extrusion die it) into the b ight of a pair of counter-rotating rolls 15 and 16. The substrate 13 to be coated is passed over roll 15 and is brought into intimate contact with film 12 in the bight of roll 15 and 16 wherein the film and substrate are bonded. From the rolls, the newly formed laminate 14 passes to further processing or to a wind up assembly.

The polyethylene'film is' air-cooledtosome extent as it traverses the span between extrusion die lip 11 and the rolls, and by contact with the cooled roll 16. It is during the period beginningwhen the film leaves the extrusion die lip until it is cooled by roll 16 that it is essential to prevent the excess of oxygen to the film. By introducing an inert gas such as nitrogen, carbon dioxide, a noble gas, etc., through gas manifold 17, it is possible to blanket the film with inert gas, thereby substantially shielding the film from oxygen.

The invention was described with respect to the particular apparatus of the figure, and with respect to the extrusion of flat film. However, these are not limitations on this invention.

It is not necessary that the process be limited to film extrusion. The odor-forming, discoloration and blocking characteristics of any extruded polyethylene may be greatly enhanced by shielding the extrusion product from oxygen. Similarly, goodproperties may be maintainedin polyethylene even though the material is heated to an elevated temperature if the material is shielded from an oxidizing atmosphere. i Even though the temperatures normally used for polyethylene fiat film extrusion do not create as serious a heat sealabilityproblem as found in the higher temperature film coating process, nevertheless, by blanketing the hot film with an inert gas, heat scalability and resistance to odor-formation and discoloration may be improved and blocking is reduced. v

An appropriately shaped hood may be employedto introduce the inert gas blanket in place of the gas manifold.

, Many other means of applying and practicing this invention will be obvious to those skilled in the art.

, Preheating thesub'strate, extruding at higher temperatures' and passing air, particularly preheated air, across the surface of the film which is to be bonded to the substrate have all been found to improve the adhesion of the to the substrate and to injure the heat scalability of the film and the other properties discussed previously. By the method of this invention, it is now possible to apply any or all of these techniques without injuring the filmheat scalability; it is only necessary that the film 'sufrfacewhich is not bonded to the substrate in the process be shielded from oxygen while at the elevated tempasture. I v p y In some cases adhesion may be still further improved by preheating the inert gas to minimize cooling of the film.

Theistes bri this invention finds wide applicability various polyethylene, and modified polyethylene compositions. p

. The following polyethylene compositions were applied to desasen, dry, annealed, one-mil-thick aluminum foil to form, a. 3.5 mil coating thereon;

I and B comprising polyethyleneresin having a melt index of 3 .1 and specific gra vi'ty of 0.92;

.,C comp sing a polyeth: lene resin having a melt index of 0.56 and a specific gravity of 0.92; v

D comprising 190 parts of A, 0.03 part commercial "grade oleamide and 01005 part 'di-tert-butyl-p-cresol as an antioxidant; these materials were Banburie'd together for about 10 minutes under'a ram pressure or 80 p.'s.i.g. with cooling water circulating through the Banbury rotor and jacket at "such arate that the mass temperature rose gradually to 120 'C. during this period; the material was then sheeted on a two-roll mill'at 100 C. for four minutes, cooled, and granulated;

E comprising 95 parts of a polyethylene resin having a melt index of 1.7 and specific gravity of 0.91, 5 parts of 'polyisobutylene having a nominal molecular weight (Standinger viscosity method) of about 20,000 (Enjays Vistanex L420),- and 0.02. part di-tert-butyl-p-cresol as an antioxidant; the materials were Banburied togetherfor 8.5 minutes under a ram pressure of 40p.s .i.g. with cooling water circulating through the Banbury rotor and jacket at such a rate-that the mass temperature rose gradually to C. during this period; the material was then sheeted on a tworoll mill for about three minutes at (1., cooled, and granulated.

The extrusion and coating operating conditions, with theexception of the extrusion atmosphere, are shown in Table I. Apparatus similar to that shown in the figure was employed.

Table I Polyethylene Extrusion Substrate Roll Film Composition Temperature Rate, Speed, Pressure, at extrusion lbs-lhr. ttl/mm. 1bS ./1ll1e3] Die Lips, C. inch In each case, part of the material was extruded with-- out oxygen shielding and the remainder was extrude'd with oxygen shielding. The final laminates were then 1 tested for initial heat scalability and for heat scalability after aging.

Initial scalability was tested as follows:

Two sections of laminated material were placed coated-face to coated-face and an approximately one inch wide seal was made with a conventional heat sealer (3 second heat at 350 F. and 40 p.s.i. pressure). A one inch wide strip was cut perpendicular to the direction of the real. h One end of this strip was attached to a fixed bar and a two pound weight clamped onto the other end in such manner that the weighted strip was freely suspended. After the strip had been so suspended for one hour at room temperature, the sealed area was carefully examined and the degree of separation which had occurred was noted.

Heat scalability after aging was tested according to the method of Military Specification MILB131B.

The coated foil was conditioned for 8 hours at 100 F. and 100% relative humidity, then for 16 hours in a F. oven, then for 8 hours at 100 F. and 100% relative humidity, then for 16 hours in a 160.F. oven. The material was then treated as for the initial scalability test.

MILE-131B rates a material as passing if the seal. delamination does not exceed inch in depth.

The results of these tests are shown in Table II.

Table H Heat Scalability Film Ooru- Extrusion position And- Atmosphere treatment Initial After Aging ir Fxoollent failed in 5 minutes. Nitrogenblanket..- do passed. A' Very good... failed in 15 minutes. N1trogen-b1anket do.. passed.

1r. Excellent failed in 2 minutes. Nitrogen blanket .d0 passe -do failedinlhour. N1trogenblanket d0 passed.

Very good failed-did not I l support weight. Nitrogen blanket. -.do passed.

As may be seen from the table, the polyethylene films, extruded at elevated temperatures for firm bonding to the substrate, must be shielded from oxygen during extrusion and until cooled if the film is to retain its heat scalability. 'By following the teachings of this invention it is possible to take advantage of high temperature treatment without having the disadvantages that "previously accompanied hightemperature treatment.

aomaae What is claimed is:

1. Method for forming a polyethylene film having one surface characterized by heat-scalability to a polyethylene surface and the other surface by adhesiveness to a nonpolyethylenic substrate which comprises extruding polyethylene as a film, immediately blanketing with an inert gas that surface of the film which is to be heat-sealable as it emerges from the extruder and until it has cooled below its heat-degradation temperature while simultaneously exposing the other surface which is to adhere to a non-polyethylenic substrate to an oxygen containing atmosphere.

2. Method according to claim 1 wherein the extrusion temperature is between about 255 C. and 275 C.

3. Method for forming a laminate of a polyethylenic film and a non-polyethylenic substrate, said laminate being characterized by an exposed heat-sealable polyethylene surface which comprises extruding a polyethylene film, immediately blanketing with an inert gas that surface of the film which is to be heat-scalable as it emerges from the extruder and until the film is adhesively bonded to a non-polyethylenic substrate while simultaneously exposing the other surface to an oxygen containing atmosphere, and immediately thereafter adhering the non-polyethylenic substrate to said other surface of the polyethylene film.

4. Process according to claim 3 wherein the non polyethylenic substrate is metallic foil.

5. Process according to claim 3 wherein the non-polyethylenic substrate is paper.

6. Process according to claim 3 wherein the non-polyethylenic substrate is cellophane.

7. A laminate comprising a nonpolyethylenic substrate and a polyethylene film, one surface of which was at least partly oxidized and is heat and pressure bonded to said nonpolyethylenic substrate, and wherein the other surface of said polyethylene film was kept unoxidized and thereby heat-scalable by continuous maintenance in an inert gas from the time of extrusion to cooling to below the heat degradation temperature of the polyethylene.

8. A laminate as in claim 7 wherein the non-polyethylenic substrate is metallic foil.

9. A laminate as in claim 7 wherein the non-polyethylenic substrate is paper.

10. A laminate as in claim 7 wherein the non-polyethylenic substrate is cellophane.

References Cited in the file of this patent UNITED STATES PATENTS 2,451,597 Wheeler Oct. 19, 1948 2,683,894 Kritchever July 20, 1954 2,714,571 Irion et a1. Aug. 2, 1955 2,715,088 Gunning Aug. 9, 1955 2,839,441 Kent June 19, 1958 FOREIGN PATENTS 538,827 Great Britain Aug. 19, 1941 OTHER REFERENCES Welding of Plastics (Haim and Zade), published by Crosby Lockwood & Son, Ltd. (London), 1947; pages -71 relied on. 

1. METHOD FOR FORMING A POLYETHYLENE FILM HAVING ONE SURFACE CHARACTERIZED BY HEAT-SEALABILITY TO A POLYETHYLENE SURFACE AND THE OTHER SURFACE BY ADHESIVENESS TO A NONPOLYETHENIC SUBSTRATE WHICH COMPRISES EXTRUDING POLYETHYLENE AS A FILM, IMMEDIATELY BLANKETING WITH AN INERT GAS THAT SURFACE OF THE FILM WHICH IS TO BE HEAT-SEALABLE AS IT EMERGES FROM THE EXTRUDER AND UNTIL IT HAS COOLED BELOW ITS HEAT-DEGRADATION TEMPERATURE WHILE SIMULTANEOULSY EXPOSING THE OTHER SURFACE WHICH IS TO ADHERE TO A NON-POLYETHYLENIC SUBSTRATE TO AN OXYGEN CONTAINING ATMOSPHERE.
 7. A LAMINATE COMPRISING A NONPOLYETHLENIC SUBSTRATE AND A POLYETHYLENE FILM, ONE SURFACE OF WHICH WAS AT LEAST PARTLY OXIDIZED AND IS HEAT AND PRESSURE BONDED TO SAID NONPOLYETHYLENIC SUBSTRATE, AND WHEREIN THE OTHER SURFACE OF SAID POLYETHYLENE FILM WAS KEPT UNOXIDIZED AND THEREBY HEAT-SEALABLE BY CONTINUOUS MAINTENANCE IN AN INERT GAS FROM THE TIME OF EXTRUSION TO COOLING TO BELOW THE LATE DEGRADATION TEMPERATURE OF THE POLYETHYLENE. 